Integrated inverter compressor variable volume refrigerant loop data center cooling unit and control system

ABSTRACT

A point to point, point to multipoint, or multipoint to multipoint integrated inverter compressor variable volume refrigerant loop data center cooling unit and control system used to regulate volume of refrigerant to air handling systems used to supply cold air ventilation to data center rooms and to the electronic equipment mounted therein which require constant cooling by using a control system controlling variable speed pumps, fans, compressors and condensers to operate a one or a plurality of closed loop, variable volume refrigerant loop systems in conjunction with one or a plurality of associated interior air handling systems located within a data center.

CROSS-REFERENCE TO RELATED APPLICATION 35 USC §119(e)

Not Applicable

FIELD OF INVENTION

This invention relates to the assembly and integration of VariableRefrigerant Flow (VRF) inverter compressors, variable speed pumps,valves, control modules, sensors and closed loop variable volumerefrigerant piping into a plurality configuration to be installed andoperated within a data center to provide point to point, point tomultipoint or multipoint to multipoint cooling capacity to various airhandling systems located within a data center used to provide airconditioning throughout the data center and adjacent rooms. Theinvention also relates to the simultaneous supply of various temperaturelevels as temperature zones within the same environment utilizing thesame system.

BACKGROUND OF INVENTION

For many decades now telecommunications, cable television and largescale information services companies have constructed and operated“data” centers as central nodes for housing equipment, interconnectingvoice and data circuits and storing information in large databases.These data centers have evolved from telephone switching centers andlarge scale computer rooms to modern day “server farms”.

Equipment miniaturization has increased the density of data trafficserved by a single chip, computer processor and server array. Increasesin fiber optic cable capacity, wireless network expansion and over-alldensity in deployment of broadband facilities which interconnectbuildings, networks and people has increased the number of data centersand the density of equipment housed within these data center facilities.

Several standards for building and operating data centers exist and oneof the standards is the control of the ambient air temperature withinthe data center which is integral in cooling of the electronics. It maybe desirable to control the temperature within the data center withinzones to conserve energy. The present invention introduces a newconfiguration for using variable refrigerant flow technology integratedwith traditional air handlers used to cool the data center environment.

Traditionally, cooling systems were designed to operate on/off and thusare not efficient at partial loads. Existing facilities may need morecooling but have limited space for additional system components. Thepiping and ducting for typical systems is large and requires use offlame/welding to install. Also, compressors are typically located insidethe indoor cooling cabinet.

Existing heat loads can be located inside a facility, which often timesmay be too far from the outside location of condenser equipment to beeconomically served by conventional systems.

The system in the present embodiment integrates Variable RefrigerantFlow (VRF) components and optimal placement of these components intoindoor and outdoor units interconnected with a closed loop refrigerantpiping network to: 1) Provide efficient cooling at all load conditions;2) provide point to point, point to multipoint, or multipoint tomultipoint configuration; and 3) allow long runs of refrigerant pipingto reach existing heat loads.

The present invention simplifies the deployment of multipointdistributed variable refrigerant flow cooling systems within the datacenter. In short, the present invention works equally well in either aprimary system or auxiliary system within the data center.

Although there are several apparatuses which may have various functionsrelated to the variable refrigerant flow multipoint distributed chilledwater cooling and control system for data centers, none of these eitherseparately or in combination with each other, teach or anticipate thecurrent invention. Therefore, there remains an unmet need in the fieldof data center cooling. The current invention will fulfill this unmetneed.

SUMMARY OF INVENTION

The following presents a simplified summary in order to provide a basicunderstanding of some aspects of the disclosed invention. This summaryis not an extensive overview, and it is not intended to identifykey/critical elements or to delineate the scope thereof. Its solepurpose is to present some concepts in a simplified form as a prelude tothe more detailed description that is presented later.

The present embodiment presents a multipoint capable cooling and controlsystem consisting of integrated variable speed pumps, valves, coils,control modules, sensors and closed loop variable flow rate refrigerantpiping network. The present embodiment consists of outdoor and indoorunits within a data center which provides data center operators greaterflexibility in deploying electronics requiring in-row temperaturecontrol and cold air flow circulation. The present invention providesfor an integrated cooling and control package which remains compatiblewith traditional air handler systems and data center environments whileexpanding capacity of such systems.

The present embodiment as described provides for controllability of fouraspects of the system which have not existed in combination prior tonow. The first aspect is the variable refrigerant flow sub-system whichallows for independent control of the refrigerant flow rate within theclosed loop refrigerant piping and distribution system. The secondaspect is the cascading assembly of coils and associated variablerefrigerant flow closed loop piping which create zone cooling capacity.The third aspect is the integrated variable control manifoldconfiguration to manage refrigerant distribution within the multipointenvironment. The forth aspect is the multi-zone configuration assemblywhich provides secondary and tertiary stage temperature control withinthe data center.

The present embodiment is a system which integrates Variable RefrigerantFlow (VRF) components with an in-row cabinet configuration loop to: 1)provide variable cooling capacity under all load conditions; 2)eliminate the need for indoor compressor installation; 3) allow for longruns of refrigerant piping to reach existing heat loads; and 4) providemultiple temperature control zones utilizing the same cooling system.

This system shown in the present embodiment varies its energy use withthe heat load and is more efficient at partial loads. It requires noindoor compressor nor does it require large piping or ducting. It isalso capable of supplying cooling to locations within a facility thatcannot be reached by typical systems. Additionally, the system isconfigurable as a point to point, point to multipoint or a multipoint tomultipoint system.

The VRF Inverter Compressor Condenser(s) utilized in the presentembodiment are required to enable the system to vary its capacity to theheat load. Refrigerant to coils contained within the indoor cabinet arecritical to the operation and integration of the system. The variablespeed pump allows refrigerant to be pumped at flow rates that match theflow required by the facility cooling equipment (Heat Load). Multipletemperature zones are accomplished by routing variable refrigerant flowsto separate coils which are configured in serial or parallel and whichare regulated by controllable valves.

The present embodiment consisting of components in the system to cool afacility in a unique way by integrating a VRF refrigerant system with aregulated variable flow rate refrigerant loop. The process begins whenrefrigerant is cooled and routed to a coil located in the indoorcabinet. Variable speed fans force air across the coil in a traditionalfashion. Circulating chilled air within the data center effectivelyenvelops the data center equipment to maintain a constant operatingtemperature within the data center or within zones within the datacenter.

The present embodiment improves upon the traditional system byincorporating VFR technology with a control system used to regulate boththe flow rate of the refrigerant and the destination of the refrigerantto coils installed within the indoor cabinets. Using combinations ofcontrollable pumps, fans, compressors and routing valves, the controlsystem within the present embodiment functions to operate a network ofcomponents to maintain air temperature within the data center.

The present embodiment consists of outdoor units (ODUs) equipped with aVRF inverter compressor and corresponding condenser(s) which areinstalled outside the facility. The indoor unit (IDUs) consists ofcoils, fans and valves and the associated control system which islocated inside the facility. The copper piping loops for refrigerant runfrom connection points located at the ODUs VFR to the connections pointsat the IDUs. A network of refrigerant piping is formed using additionalcontrollable vales to create multipoint distribution networks of coolingcapacity.

Sensors are installed which air temperature temp and refrigerant temp,flow and pressure. This measurement data is processed by the controlsystem which controls the automatic valves, the pump and the ODUs tosignal necessary changes in capacity (compressor speed).

The facility equipment (heat load) to be cooled by the system shown inthe present embodiment should be identified and the required coolingcapacity calculated. Then the system is sized and configured to deliverthe required flow rate and fan speed.

The logic required to make the system presented in the presentembodiment work efficiently and seamlessly is programmed into thecontrols. Data from various sensors is used as follows:

-   -   Outdoor air temp increasing=Compressor/Condenser speed        increasing    -   Outdoor air temp decreasing=Compressor/Condenser speed        decreasing    -   Return refrigerant temp increasing=Compressor/Condenser speed        increasing    -   Return refrigerant temp decreasing=Compressor/Condenser speed        decreasing    -   Rack air temp increasing=Fan Speed Increasing    -   Rack air temp decreasing=Fan Speed Decreasing

Still other objects of the present invention will become readilyapparent to those skilled in this art from the following descriptionwherein there is shown and described the embodiments of this invention,simply by way of illustration of the best modes suited to carry out theinvention. As it will be realized, the invention is capable of otherdifferent embodiments and its several details are capable ofmodifications in various obvious aspects all without departing from thescope of the invention. Accordingly, the drawing and descriptions willbe regarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

Various exemplary embodiments of this invention will be described indetail, wherein like reference numerals refer to identical or similarcomponents, with reference to the following figures, wherein:

FIG. 1 is a detailed view of the preferred embodiment illustrating theessential components of the indoor unit.

FIG. 2 is a detailed view of the preferred embodiment illustrating theessential components of the outdoor unit.

FIG. 3 is a detailed view of the preferred embodiment illustrating amultiple coil the indoor manifold assembly.

FIG. 3a is a detailed view of the preferred embodiment illustrating asingle coil configuration.

FIG. 4 is a detail view of the preferred embodiment illustrating theessential components of the outdoor unit, indoor unit and pipingconfigured as a point to point application within a data center.

FIG. 5 is a perspective view of the preferred embodiment illustratingpoint to multipoint data center application.

FIG. 6 is a perspective view of the preferred embodiment illustratingmultipoint to multipoint data center application.

DETAILED DESCRIPTION

The claimed subject matter is now described with reference to thedrawings. In the following description, for purposes of explanation,numerous specific details are set forth in order to provide a thoroughunderstanding of the claimed subject matter. It may be evident; however,that the claimed subject matter may be practiced with or without anycombination of these specific details, without departing from the spiritand scope of this invention and the claims.

The present embodiment shown in FIG. 4 can be understood by looking atthe integrated inverter compressor variable volume refrigerant loop datacenter cooling unit and control system 100 as four sub-systems: 1)outdoor system 200; 2) indoor system 300; 3) closed loop refrigerantpiping 400; and 4) control system 500.

In FIG. 4, application of the integrated inverter compressor variablevolume refrigerant loop data center cooling unit and control system 100is illustrated by showing the data center envelop 110 which is thevolume of space defined as the data center to be cooled.

FIG. 4 presents illustration of the outdoor sub-system 200 withadditional detail shown in outdoor units 210 FIG. 2 which contain theinverter compressor 220, condenser 230 and variable speed fans 240.These sub-system components can be operated with or without redundancyand are controlled by the control system 500.

FIG. 4 also presents illustration of the closed loop refrigerant pipingsystem 400 which consists of small diameter pipe 410 forming long runs430. The supply side of the closed loop refrigerant piping smalldiameter pipe 410 is connected to the indoor supply manifold 305 FIG. 1,at connection point 470. In FIG. 4, the supply side of the closed looprefrigerant piping small diameter pipe 410 is connected to the invertercompressor 220 at connection point 260. The long runs 430 consist ofsmall diameter pipe 410 and connect the indoor coil 320 to thecompressor 220 and condenser 230 to effectuate the cooling effect of thesystem

As shown in FIG. 4, the return side of the closed loop refrigerantpiping small diameter pipe 410 is connected to the indoor return valve348 FIG. 3 at connection point 475 FIG. 1. In FIG. 4, the return side ofthe closed loop refrigerant piping small diameter pipe 410 is connectedto the inverter compressor 220 at connection point 265.

In FIG. 4, the data center envelope 110 is shown which contains theindoor system 300 and control system 500. FIG. 4 also shows the heatrecovery box 440 connected to the auxiliary water heater air heater 460using auxiliary refrigerant distribution lines 450 which is used todivert refrigerant to auxiliary units to recover heat which can be usedto heat water or heat adjacent rooms to the data center where desirable.

FIG. 4 illustrates of the indoor sub-system 300 which contains theindoor air handler unit 310 which is a cabinet 505 containing an indoorcoil 320, control valves 340 detailed as in FIG. 3 as valves 341, 342,343, 344, 345, 346, 347 and 348; fans 330; and, the control system 500which has a plurality of temperature sensors 510 within the data centerenvelop 110. Routing piping 420 is shown in FIG. 1. A plurality ofindoor coils 321, 322 and 323 FIG. 3 can be connected to control valves340 FIG. 4, detailed in FIG. 3 as 341, 342, 343, 344, 345, 346, 347 and348 to supply a plurality of zones each maintained at a differenttemperature within the data center envelop 110. As shown in FIG. 3a , asingle control valve 343, an expansion value controlling refrigerantflow to a single coil 323 is suitable for operations requiring a singletemperature zone.

The preferred embodiment as illustrated in FIG. 3a and FIG. 3 providesfor single coil 320 configuration or multiple coil 321, 322 and 323configurations, respectively, or any combination thereof. Thisconfiguration flexibility provides for redundancy of components toprevent down time due to individual coil 321, 322 or 323 failure andwhich also provides for in-service maintenance and service capabilitiesof the system 100 without having to take the system 100 out of servicecompletely to perform maintenance or repairs.

The preferred embodiment as illustrated in FIG. 3 can be configured todistribute refrigerant to each coil 321, 322 and 323 individually byadjusting control valves 341 through 348 respectively. To isolate coil323, control valves 343 and 346 would be activated to create a closedloop. To cascade coil 322 and 323, control valves 342, 343, 344 and 346would be activated to create a closed loop. To cascade coils 321, 322,323, all control valves will be activated to create a continuous closedloop circulating refrigerant through all three coils 321, 322 and 323.

The capacity of cooling provided by the system 100 FIG. 4 is a functionof control provided by the control system 500. The control system 500can adjust the flow rate of refrigerant within the close looprefrigerant piping 400 to the coil 320, or coils 321, 322 and 323 when aplurality of coils is configured.

Additionally, as illustrated in FIG. 5, a point to multipoint network ofindoor systems 301 and 302 is created by connecting mid-span controlvalve 349 to control the distribution of refrigerant flow, throughrefrigerant piping branches in the closed loop refrigerant piping 400described below, to multiple indoor systems 301 and 302.

As shown in FIG. 6, a multipoint to multipoint network of outdoorsystems 200 to indoor systems 300 is illustrated using a mid-spancontrol valve 349 to serve a plurality of data center envelops 110, 120and 130. A plurality of temperature sensors 510 are positioned withinthe data center envelops 110, 120 and 130 as shown in FIG. 5 and FIG. 6.

The multipoint to multipoint system is created as shown in FIG. 6, wherea plurality of outdoor units 211 and 212 are connected to a plurality ofindoor units 301 shown as an inrow system, 302 shown as a CRAC systemand 303 shown as a perimeter system using a mid-span control valve 349to supply multiple branches 401, 402 and 403 within the closed looprefrigerant piping 400 shown as branch 401, 402 and 403 supplying indoorunit 301, 302 and 303 respectively.

In FIG. 4, the volume of refrigerant circulating in the closed looprefrigerant piping system 400 is control directly by adjusting the speedof the inverter compressor 220 by the control system 500. The volume ofrefrigerant circulating within the close loop refrigerant piping 400 isdirectly proportional to the cooling capacity available to the heat loadwith the data center envelop 110, FIG. 4. Increasing the flow rate ofrefrigerant circulating provides higher capacity to maintain thetemperature of the data center envelop 110 constant when higher heatload is present.

In FIG. 4, the control system 500 also provides control to the outdoorsystem 200 controlling the inverter compressor 220, condenser 230 andvariable speed fans 240. This combined control of outdoor system 200 andindoor system 300 provides operating efficiencies which are not found inother systems. The control system 350 operates to ensure the outdoorsystem 200 is operating at the most efficient speed to yield the optimumlevel of heat transfer from the refrigerant contained with the closedloop refrigerant line which was absorbed through the coil 320.

The control system 500 FIG. 4 accepts inputs signals from a plurality oftemperature sensors 510 distributed throughout the data center envelop110. According with logic within the control system 500, control signalsare transmitted to the sub-systems to adjust the speed of the variablespeed components and which controls the refrigerant flow rate within theclosed loop refrigerant piping branches 401, 402 and 403 as shown inFIG. 6, by controlling mid-span valve 349, which supply a plurality ofcoils 321, 322, and 323 contained within the indoor system 300 shown inFIG. 3. The flow rate to individual coils 321, 322 and 323, FIG. 3, iscontrolled to create temperature zones within the data center envelop110 which is accomplished by the control system 500 controlling indoorsupply manifold 305 FIG. 1 to control the flow rate of refrigerant toeach respective control valve 341, 342, 343, 344, 345, 346, 347 and 348FIG. 3 respectively. Controlling the flow rate of refrigerant anddistributing the refrigerant to various coils yields the maximumcapacity for heat transfer with minimum demand for consumable servicessuch as power consumption and wear on friction bearings contained withinthe compressors and fans.

It may be advantageous to set forth definitions of certain words andphrases used in this patent document. The term “couple” and itsderivatives refer to any direct or indirect communication between two ormore elements, whether or not those elements are in physical contactwith one another. The terms “include” and “comprise,” as well asderivatives thereof, mean inclusion without limitation. The term “or” isinclusive, meaning and/or. The phrases “associated with” and “associatedtherewith,” as well as derivatives thereof, may mean to include, beincluded within, interconnect with, contain, be contained within,connect to or with, couple to or with, be communicable with, cooperatewith, interleave, juxtapose, be proximate to, be bound to or with, have,have a property of, or the like.

What has been described above includes examples of the claimed subjectmatter. It is, of course, not possible to describe every conceivablecombination of components or methodologies for purposes of describingthe claimed subject matter, but one of ordinary skill in the art canrecognize that many further combinations and permutations of such matterare possible. Accordingly, the claimed subject matter is intended toembrace all such alterations, modifications and variations that fallwithin the spirit and scope of the appended claims. Furthermore, to theextent that the term “includes” is used in either the detaileddescription or the claims, such term is intended to be inclusive in amanner similar to the term “comprising” as “comprising” is interpretedwhen employed as a transitional word in a claim.

While this disclosure has described certain embodiments and generallyassociated methods, alterations and permutations of these embodimentsand methods will be apparent to those skilled in the art. Accordingly,the above description of example embodiments does not define orconstrain this disclosure. Other changes, substitutions, and alterationsare also possible without departing from the spirit and scope of thisdisclosure, as defined by the following claims.

We claim:
 1. An integrated inverter compressor variable volumerefrigerant loop data center cooling unit and control system used tomaintain air temperature control and distribute cold air within datacenters consisting of: outdoor inverter compressor; and, outdoorvariable speed fan; and, outdoor variable volume condenser coil; and, avariable volume refrigerant loop; and, indoor electronic valves; and,Indoor and outdoor headers; Indoor coil; and, Indoor variable speed fan;and, a control system.
 2. The integrated inverter compressor variablevolume refrigerant loop data center cooling unit and control system inclaim 1 which can be configured as a point to point, point to multipointand multipoint to multipoint system.
 3. The integrated invertercompressor variable volume refrigerant loop data center cooling unit andcontrol system in claim 1 which can be configured as an in-row, computerroom air conditioner “CRAC”, rear door air handler, overhead airhandler, or underfloor cooling units.
 4. The integrated invertercompressor variable volume refrigerant loop and data center cooling unitand control system in claim 1 which can be configured as modules to formmultipoint networks of indoor and/or outdoor nodes to scale the capacityof the integrated system to cool variable load demands.
 5. Theintegrated inverter compressor variable volume refrigerant loop and datacenter cooling unit and control system in claim 1 which consists of amultitude of separately configured indoor coils to produce different airtemperature air flow outputs within the same data center resulting inseparately controlled zoned air temperature control within the datacenter.
 6. The integrated inverter compressor variable volumerefrigerant loop and data center cooling unit and control system inclaim 1 with an electronic system for controlling cooling with a datacenter or auxiliary space comprising: A memory storing instructions;and, at least one processor configured to execute the instructions; and,at least one sensor(s) to detect air temperature within the cabinet;and, at least one sensor(s) to detect proper operation of the variableflow refrigerant loop distribution system; and, A management system todetect and generate a response to activate air cooling system;distribution system, generate a response to activate and control fan,pump, compressor and condenser speed; generate a response to controlvalves through which the refrigerant flows; generate a response tocontrol variable controls of operation of the variable cooling system;generate a response to control header valves to mix point to point,point to multipoint, and multipoint to multipoint refrigerant flowpaths; and, generate a response to maintain operation of the integratedsystems to achieve cost efficiencies of the operational system.